sensors

Article
A Low-Cost Surge Current Detection Sensor with
Predictive Lifetime Display Function for Maintenance
of Surge Protective Devices
Youngjun Lee 1,2 and Young Sam Lee 1, *
1 Department of Electrical Engineering, 100 Inha-ro, Michuhol-gu, Inha University, Incheon 22212, Korea;
yjl0717@empal.com
2 Sungjin Techwin Co., Ltd., 62, Yuseong-daero 877 beon-gil, Yuseong-gu, Daejeon 34127, Korea
* Correspondence: lys@inha.ac.kr; Tel.: +82-32-860-7403




Received: 3 March 2020; Accepted: 16 April 2020; Published: 18 April 2020


Abstract: In this study, a low-cost surge current detection sensor (SCDS) that can measure high
current surges using a low-current toroidal coil is proposed for maintenance of a surge protective
device (SPD). The proposed SCDS is designed to display the predicted lifetime of the SPD based
on the magnitude of surge current and number of surges. In addition, a method for measuring
high surge current using a toroidal coil that can usually measure only low current is proposed. A
lightning strike counter consists of a microcontroller with a low-power liquid crystal display (LCD)
driver, 3 VDC lithium battery, and signal conditioning circuit that converts amplitude information
of the surge current into duration information of a negative pulse to facilitate processing in the
microcontroller. In this paper, we propose a software algorithm that can calculate the remaining
lifetime of SPD based on the amplitude and number of surge currents. There is also an option to
select the capacity of the surge protective device and the number of phase lines, allowing it to assess
the predicted lifetime for various types of Class II SPDs. The proposed SCDS is measured as 7.2 µA
from the battery power consumption test, and the service life is calculated to be 11.1 years. It meets
the International Standard IEC62561-6 test conditions of the lightning strike counter and is expected
to be useful in the maintenance of SPDs and lightning protection systems.

Keywords: surge current detection sensor; lightning strike counter; low-cost surge current detection
sensor; surge protective device (SPD); maintenance of SPDs; predictive lifetime of SPD

1. Introduction
Surge protective devices (SPDs) for low-voltage power distribution systems are essential for the
operation of electrical systems. SPDs installed in building power distribution systems and industrial
applications are generally used to ensure continuous operation [1]. SPDs eliminate electrical surges or
impulses by acting as a low impedance path that turns the transient voltage into a current and shunts
it along the return path, usually ground. By design, an SPD often acts as a ‘self-sacrifice’ device. In
other words, the primary purpose of an SPD is to remove harmful voltage spikes from an electrical
system even in conditions potentially harmful to the SPD. SPDs should not stop operating even if the
circuit breaker is activated, the nearby system is damaged, or if there is smoke that causes a physical
hazard to humans [2]. A metal oxide varistor (MOV) is widely used in low-voltage power systems
as a core component in surge protectors because of its technical advantages and low cost. However,
an MOV carries the risk of thermal runaway at the end of its lifetime. Thermal runaway tends to result
in electrical hazards, such as short circuits or explosions. Thus, the MOV is designed with a thermal
fuse spring or thermal fuse to prevent thermal runaway [3–10].

Sensors 2020, 20, 2310; doi:10.3390/s20082310 www.mdpi.com/journal/sensors

Sensors 2020, 20, 2310 2 of 17

In the test list of the International Standard IEC61643-11 for surge protective devices, the thermal
stability test is important for investigating the potential combustion and explosion of SPDs at the
end of the MOV lifetime. The lifetime of the MOV is assessed by the amplitude of the surge current,
the amount of energy, and the number of surges. The transient surge current flowing into the SPD
is usually measured using a current transformer (CT) or Rogowski coil. CTs require a high current
detection range and high frequency characteristics to measure transient surge currents, and they can
cost thousands of dollars. The Rogowski coil is significantly less expensive, costing several hundred
dollars, but is still relatively expensive compared to an SPD. Typical single-phase and three-phase
Class II In 20-kA SPDs cost less than one hundred dollars [11–18]. For this reason, SPDs are rarely used
with devices that can estimate lifetime. For maintenance, SPDs are typically replaced by electrical
facility managers when they are thought to be at the end of their lifetime based on verification through
a status indicator. A remote-control method can identify the signal output from the remote terminals
of the SPD, but it is rarely used as the installation of additional communication modules presents a
cost issue. Another option is a surge counter can be installed in the SPD [19,20]. If lightning current
above the critical current level flows in, the count of the surge counter increases. However, this does
not indicate the remaining lifetime of the SPD. At the end of the lifetime of the SPD, it can no longer
protect electrical devices from surges because it is separated from the electrical distribution system.
Therefore, a device that can measure the predicted lifetime of an SPD at a market-acceptable cost is
necessary. In this study, a surge current detection sensor (SCDS) with a reasonable cost is proposed
that can estimate the remaining lifetime of an SPD. The proposed SCDS consists of a low-cost current
sensor using small wound toroidal cores composed of iron powder, a signal conditioning circuit for
converting the amplitude of a surge to duration width of a negative pulse for easy processing in a
low-voltage microcontroller, a 3 V coin-cell battery, and a low-cost liquid crystal display (LCD) to
predict the lifetime of the SPD based on the magnitude of surge currents and number of surges. In this
study, we propose a low-cost SCDS and a predictive lifetime software algorithm for estimating the
SPD predictive lifetime for the maintenance of the SPD.

2. Materials and Methods

2.1. Mechanical Design

The proposed SCDS is relatively small, with a size of 50.0 mm × 106.0 mm × 68.4 mm. The
enclosure is composed of flame-retardant plastic and has a Protective Earth (PE) terminal connected to
ground and a PE connection terminal connected to the SPD. For protection from electrical shock, the
SCDS has a terminal block cover that meets the IP20 waterproof and dustproof rating. IP20 requires
that the conductors of the SCDS are protected from human contact. The SCDS also has an LCD window
and a function key on the top. For installation, it can be mounted on an EN 60715 DIN rail, which is
the widely used mounting standard for electric devices such as circuit breakers. Figure 1a presents an
external image of the SCDS; an image of the SCDS installed with the SPD is shown in Figure 1b.

2.2. Block Diagram

Lightning causes transient surge voltage to the phase and neutral line of the SPD. The metal oxide
varistor (MOV) and gas discharge tube (GDT) of the SPD limit the transient surge voltage and divert
the surge current to PE. The surge current flows from the PE terminal of the SPD into PE through a
low-cost current sensor using toroidal cores. The SCDS consists of the current sensor using toroidal
cores with windings and a signal conditioning circuit for converting the amplitude of surge current to
duration width of a negative pulse for microcontroller processing with a low operation voltage of 3 V.
In addition, it uses a 3 V/1000 mAH coin-cell type battery for operation without an external power
supply, and a low-cost liquid crystal display (LCD) to show the predictive lifetime of the SPD based
on the amplitude of surge currents and the number of surges. Figure 2 shows the block diagram of
the SCDS.
Sensors 2020, 20, 2310 3 of 17
Sensors 2020, 20, x FOR PEER REVIEW 3 of 18

(a)
(b)
Figure 1. (a) Surge current detection sensor (b) Example of surge current detection sensor installed
with a surge protective device (SPD).

2.2. Block Diagram

Lightning causes transient surge voltage to the phase and neutral line of the SPD. The metal
oxide varistor (MOV) and gas discharge tube (GDT) of the SPD limit the transient surge voltage and
divert the surge current to PE. The surge current flows from the PE terminal of the SPD into PE
through a low-cost current sensor using toroidal cores. The SCDS consists of the current sensor using
toroidal cores with windings and a signal conditioning circuit for converting the amplitude of surge
current to duration width of a negative pulse for microcontroller processing with a low operation
voltage of 3 V. In addition,(a) it uses a 3 V/1000 mAH coin-cell type battery for operation without an
(b)
external power supply, and a low-cost liquid crystal display (LCD) to show the predictive lifetime of
Figure
the Figure
(a)
SPD1.based on1.the
Surge (a) Surge current
current
amplitude ofdetection
detection sensor
sensor
surge (b)(b)Example
currents Example
and the of
ofsurge
surge
number current detection
ofcurrent
surges. sensor
detection
Figure installed
sensorthe
2 shows installed
block
with a surge protective device (SPD).
with a surge
diagram protective
of the SCDS. device (SPD).
2.2. Block Diagram
Lightning causes transient surge voltage to the phase and neutral line of the SPD. The metal
oxide varistor (MOV) and gas discharge tube (GDT) of the SPD limit the transient surge voltage and
divert the surge current to PE. The surge current flows from the PE terminal of the SPD into PE
through a low-cost current sensor using toroidal cores. The SCDS consists of the current sensor using
toroidal cores with windings and a signal conditioning circuit for converting the amplitude of surge
current to duration width of a negative pulse for microcontroller processing with a low operation
voltage of 3 V. In addition, it uses a 3 V/1000 mAH coin-cell type battery for operation without an
external power supply, and a low-cost liquid crystal display (LCD) to show the predictive lifetime of
the SPD based on the amplitude of surge currents and the number of surges. Figure 2 shows the block
diagram of the SCDS.

Figure 2. Block diagram of the proposed surge current detection sensor (SCDS).
Figure 2. Block diagram of the proposed surge current detection sensor (SCDS).

The The
interior consists of a current sensor PCB and a main PCB. The installed PCB is shown in
interior consists of a current sensor PCB and a main PCB. The installed PCB is shown in
Figure 3. Sensors 2020, 20, x FOR PEER REVIEW
Figure 3.
4 of 18

Figure 2. Block diagram of the proposed surge current detection sensor (SCDS).

The interior consists of a current sensor PCB and a main PCB. The installed PCB is shown in
Figure 3.

Figure3.3. PCBs
Figure PCBs ofofthe SCDS.
the SCDS.
2.3. Lightning Surge

2.3.1. Classification of Surges

Surge transient voltages are caused by the switching operation (on/off) of electrical loads used
in a building, and sometimes by magnetic and inductive coupling due to the formation of magnetic
fields as large currents flow. Surges are also caused by static electricity and lightning strikes, which
are classified as direct and induced lightning strikes. Direct lighting strikes travel directly through
Sensors 2020, 20, 2310 4 of 17

2.3. Lightning Surge

2.3.1. Classification of Surges

Surge transient voltages are caused by the switching operation (on/off) of electrical loads used
in a building, and sometimes by magnetic and inductive coupling due to the formation of magnetic
fields as large currents flow. Surges are also caused by static electricity and lightning strikes, which
are classified as direct and induced lightning strikes. Direct lighting strikes travel directly through
lightning rods or antennas and can damage electronic devices through high energy impulse-induced
strike currents. When a direct lightning strike hits a line, the surge current is divided into two parts by
the flow direction. The surge voltage is determined by the surge impedance of the line and the surge
current [12].
Z×I
V= (1)
2
where V is the surge voltage, Z is the surge impedance of the line, and I is the surge current. Assuming
a surge current of 10 kA and a surge impedance of 400 Ω, the surge voltage is calculated to be 2000 kV
by Equation (1). Owing to changes in the electromagnetic field that occur during lightning strikes,
surges can also occur on power lines that are far from the lightning strike. The surge voltage of the
induced lightning can be obtained from [12]

h
V = 30 × k × ( ) × I (2)
d
where V is the prospective surge voltage, I is the lightning current, h is the height above the ground
of the conductors, k is a factor depending on the velocity of the return stroke of the lightning strike
path, and d is the distance away from the lightning strike. The value of k generally lies in the range of
Sensors
1.0–1.3.2020,
For20,example,
x FOR PEERtheREVIEW
surge voltage caused by a lightning strike at a distance of 1 km under a 5surge of 18

current of 10 kA and a line height of 5 m is calculated to be 1.5 kV. High surge voltage is also generated
is
byalso generated
an induced by an induced
lightning strike. Alightning strike. Acurrent
direct lightning direct lightning
may amountcurrent may amount
to hundreds of kA,to which
hundreds
can
of kA,
cause damage from induced lightning strikes at a distance of tens of km. Damage to electronicDamage
which can cause damage from induced lightning strikes at a distance of tens of km. devices
to electronic
caused devicesstrikes
by lightning caused by lightning
is usually strikes is
from induced usually Therefore,
lightning. from induced lightning.
to prevent damageTherefore,
caused byto
prevent damage caused by lightning strikes, an SPD is used as indoor lightning
lightning strikes, an SPD is used as indoor lightning protection in buildings [12]. The international protection in
buildings [12]. The international
standard waveforms of lightning surgestandard
currentwaveforms of lightning
for direct and surge current
induced lightning strikes for direct and
are depicted in
induced
Figure 4, lightning strikes
and associated are depicted
parameters in Figurein4,Table
are presented and 1associated
[11,12]. parameters are presented in
Table 1 [11,12].

(a) (b)

Figure 4. (a) Direct lightning surge current waveform (b) Induced lightning surge current waveform.
Figure 4. (a) Direct lightning surge current waveform (b) Induced lightning surge current
waveform.
Here, O1 is the virtual origin, I is the peak current, T1 is the front time, and T2 is the time to half
value. Iimp is the impulse discharge current, the SPD capacity of Class I that can withstand a 10/350 µs
Table 1. Parameters of lightning surge current waveforms.

Lightning Surge Current T1 [µs] T2 [µs] SPD Class SPD Capacity

Direct 10 350 classⅠ
Induced 8 20 classⅡ

Here, is the virtual origin, is the peak current, is the front time, and is the time to
half value. is the impulse discharge current, the SPD capacity of Class I that can withstand a
Sensors 2020, 20, 2310 5 of 17

surge current flowing through the SPD. In is the nominal discharge current, which is the SPD capacity
of Class II that can withstand an 8/20 µs surge current flowing through the SPD.

Table 1. Parameters of lightning surge current waveforms.

Lightning Surge Current T1 [µs] T2 [µs] SPD Class SPD Capacity

Direct 10 350 class I Iimp
Induced 8 20 class II In

2.3.2. Lifetime of MOV

The derating curves of the In 20 kA MOV (manufactured by TDK Electronics) used as a core
component in Class II SPDs are presented in Figure 5 [21], where In is an 8/20 µs current that flows
through the SPD and is the nominal discharge current for a Class II SPD. Figure 5 shows that the
number of endurable surges is determined by the amplitude of the surges and their duration time.
For a duration time of 20 µs, the rated number of surges exponentially increases as the amplitude of
the surge current decreases. The lifetime of the MOV can be calculated based on the amplitude and
number ofSensors
surge currents.
2020, 20, x FOR PEER REVIEW 6 of 18

FigureFigure 5. Derating
5. Derating curvesofofIn 20
curves 20 kA
kAmetal
metaloxide varistor
oxide (MOV).
varistor (MOV).

2.4.Coil
2.4. Toroidal Toroidal
TypeCoil Type Current
Current SensorSensor
andand SignalConditioning
Signal Conditioning Circuit
CircuitDesign
Design
2.4.1. Toroidal Coil Type Current Sensor
2.4.1. Toroidal Coil Type Current Sensor
Generally, surge current is detected using a current transformer (CT). To measure high surge
Generally,
current,surge current
a Rogowski coil is
or detected using
a large current a current
transformer (CT)transformer (CT). To
with good frequency measure ishigh surge
characteristics
current, a Rogowski coilCTs
used. However, or aare
large current
costly and nottransformer (CT)three
economical. Thus, with good frequency
inexpensive characteristics
toroidal cores (Part No. is used.
However, C27-B11)
CTs are from Core
costly Electronics
and composed of
not economical. ordinary
Thus, ironinexpensive
three powder are used [22]. The
toroidal toroidal
cores current
(Part No. C27-B11)
sensor with a ∅1.2 winding of 11 turns around the toroidal core is shown in Figure 6. The material
from CoreandElectronics composed of ordinary iron powder are used [22]. The toroidal current sensor
dimensions of the toroidal core are presented in Table 2.
with a ∅1.2 winding of 11 turns around the toroidal core is shown in Figure 6. The material and
dimensions of the toroidal core are presented in Table 2.

Table 2. Dimensions and material characteristics of three toroidal cores.

Inner Outer Frequency

Part No. Height Material
Diameter Diameter Range
Iron powder and small
C27-B11 14.48 mm 26.92 mm 11.1 × 3 mm 500 kHz
(a) other
(b) mixtures
Figure 6. (a) Shape of toroidal core (b) Toroidal current sensor.

Table 2. Dimensions and material characteristics of three toroidal cores.

Inner Outer Frequency

Part No. Height Material
Diameter Diameter Range
Iron powder and
C27-B11 14.48 mm 26.92 mm 11.1 × 3 mm 500 kHz
small other mixtures
 Generally, surge current is detected using a current transformer (CT). To measure high surge
current, a Rogowski coil or a large current transformer (CT) with good frequency characteristics is
used. However, CTs are costly and not economical. Thus, three inexpensive toroidal cores (Part No.
C27-B11) from Core Electronics composed of ordinary iron powder are used [22]. The toroidal current
Sensors
sensor2020,
with ∅1.2 winding of 11 turns around the toroidal core is shown in Figure 6. The material
20,a2310 6 of 17

and dimensions of the toroidal core are presented in Table 2.

(a) (b)
Figure 6. (a)
(a) Shape
Shape of
of toroidal
toroidal core (b) Toroidal current sensor.
sensor.

2.4.2. Signal Conditioning Circuit

Table 2. Dimensions and material characteristics of three toroidal cores.
The signal conditioning
Inner circuit used for the detection of the surge current prevents
Outer magnetic
Frequency
Part
saturation No. Height Material
Sensors 2020, of
20, the toroidal
x FOR PEER core andDiameter
REVIEW
Diameter converts the amplitude of the surge current to the duration
Rangewidth
7 of of
18
a negative pulse. The signal conditioning circuit diagram is shown in Figure
Iron powder and 7.
C27-B11 14.48 mm 26.92 mm 11.1 × 3 mm 500 kHz
small other mixtures

2.4.2. Signal Conditioning Circuit

The signal conditioning circuit used for the detection of the surge current prevents magnetic
saturation of the toroidal core and converts the amplitude of the surge current to the duration width
Thick line (AWG9)

of a negative pulse. The signal conditioning circuit diagram is shown in Figure 7.

Figure 7. Signal conditioning circuit for detecting the surge current.

Figure 7. Signal conditioning circuit for detecting the surge current.
The voltage V1 induced on the secondary side by the surge current I to the PE on the primary side
of theThe
toroidal coil is induced
voltage proportional to the
on the time derivative
secondary of the
side by the magnetic
surge currentflux.
I to the PE on the primary
side of the toroidal coil is proportional to the time derivative of the magnetic flux.
∂B
V1 = −nA × (3)
= − ×∂t (3)
where n is the number of secondary windings, A is the area of the core’s cross section, and B is the
where
magneticn isflux,
the number
which isofproportional
secondary windings, A is theI.area
to surge current of the core’s
Generally, cross section,
iron toroidal andnot
coils are B isused
the
magnetic flux, which is proportional to surge current I. Generally, iron toroidal
to measure high-surge current due to magnetic saturation. However, in Figure 7, the PE terminals coils are not used to
measure high-surge current due to magnetic saturation. However, in Figure
are directly connected as shown by the thick line (American Wire Gauge, AWG9), and the thin line 7, the PE terminals are
(AWG21)connected
directly is connectedas through
shown by thethe thick
center linetoroidal
of the (American Wire
coil to Gauge,
prevent AWG9),
magnetic and the Magnetic
saturation. thin line
(AWG21) is connected through the center of the toroidal coil to prevent magnetic
saturation is prevented because the direct connection depicted by the thick line carries high current, saturation.
Magnetic saturationdepicted
and the connection is prevented
by thebecause
thin linethe direct the
through connection
toroidal depicted
coil carriesbylow
thecurrent.
thick line carries
The high
resistance
current, and the connection depicted by the thin line through the toroidal
value of AWG21 is approximately 16 times higher than that of AWG9. Moreover, the cable length of coil carries low current.
The resistance
AWG21 is twicevalue of AWG21
the length is approximately
of AWG9. The resistance 16 can
times behigher thanas
calculated that
[23]of AWG9. Moreover, the
cable length of AWG21 is twice the length of AWG9. The resistance can be calculated as [23]
l
R=ρ , (4)
=A , (4)

where
where RR is
is the resistance, ρ isisthe
the resistance, theresistivity, AA
resistivity, is is
the area
the ofof
area the cross
the section,
cross and
section, andl is the length.
is the length.
The current flowing in the wire is governed by Kirchhoff's Current Law [24]. Thus, magnetic
The current flowing in the wire is governed by Kirchhoff’s Current Law [24]. Thus, magnetic
saturation of
saturation of the
the toroidal
toroidal core
core with
with high
high current
current surges
surges is
is prevented. The area
prevented. The area of
of the
the cross
cross section,
section,
resistance, and current distribution rate according to cable length are shown in Table 3. The proposed
method can withstand current up to 30 times the maximum current that can be measured by the
toroidal core.

Table 3. American Wire Gauge (AWG) 9 and AWG24 characteristics.

Sensors 2020, 20, 2310 7 of 17

resistance, and current distribution rate according to cable length are shown in Table 3. The proposed
method can withstand current up to 30 times the maximum current that can be measured by the
toroidal core.

Table 3. American Wire Gauge (AWG) 9 and AWG24 characteristics.

Cross-Sectional Resistance Cable Length Connection Current Distribution

AWG
Area (mm2 ) (Ω/m) (mm) Resistance (Ω) Rate (%)
9 6.63 0.0026 30 0.001 97
24 0.205 0.0842 60 0.029 3

In the International Standard IEC61643-11, the maximum surge currents allowed in lines of the
SPD in Class I and Class II are Iimp 25 kA and In 20 kA, respectively. The currents of I and i divided from
the total surge current flowing through the path of PE are presented in Table 4, and examples of the
current distribution according to single-phase and three-phase power are illustrated in Figure8 8of [11,12].
Sensors 2020, 20, x FOR PEER REVIEW 18

Table 4. MaximumNumber
Surge current
of values according
Maximum SurgetoCurrent
single-phase and three-phase
Maximum power
Surge that flow
Current
Description
through the Protective Earth (PE) path.
Power Lines (Induced, 8/20 µs, 20 ) (Direct, 10/350 µs, 25 )
2 (line,
Description Number of i3
Power Lines 40 kA Surge Current
Maximum
Total Total 50 kASurge Current
Maximum
neutral): (Induced, 8/20 µs, In 20 kA) (Direct, 10/350 µs, Iimp 25 kA)
Single-phase
I
2 (line, neutral): i3
38.67 kATotal 40 kA kA 50 kA
48.34 Total
Single-phase i I 1.33 kA 38.67 kA 1.66 kA48.34 kA
4 (R, S, T,i 1.33 kA 1.66 kA
Total 80 kA Total 100 kA
neutral): i5
4 (R, S, T, neutral): i5 Total 80 kA Total 100 kA
Three-phase
Three-phase I I 77.34 kA 77.34 kA 96.67 kA
96.67 kA
i i 2.66 kA 2.66 kA 3.33 kA3.33 kA

Figure 8. Example circuit for maximum surge current that flows through the PE path.
Figure 8. Example circuit for maximum surge current that flows through the PE path.
The magnetic saturation threshold of the surge current (8/20 µs) flowing through the toroidal coil
The magnetic saturation threshold of the surge current (8/20 µs) flowing through the toroidal
is 3.3 kA, as measured by an experiment. Thus, a current of up to 100 kA can be measured by the
coil is 3.3 kA, as measured by an experiment. Thus, a current of up to 100 kA can be measured by the
SCDS. Because the output voltage may be high proportional to the current, the V2 voltage is reduced
SCDS. Because the output voltage may be high proportional to the current, the voltage is reduced
by connecting
by connecting Ω) in
R1 (100 (100 Ω)series with
in series the
with output
the outputof ofthe
the toroidal coil.The
toroidal coil. The bridge
bridge diode
diode ( (BD ) is used
) is 1used
to detect both positive and negative surge voltages using the R3000 from RECTRON
to detect both positive and negative surge voltages using the R3000 from RECTRON Semiconductor. Semiconductor.
Considering
Consideringthe the
high surge
high surgevoltage
voltageinput,
input,aacomponent
component with withthe
themaximum
maximum repetitive
repetitive peakpeak
reversereverse
voltage is chosen.
voltage TheThe
is chosen. peak voltage
peak of the
voltage surge
of the is ischarged
surge throughC1 and
chargedthrough anddischarged through R2 and
discharged through
and —there is no other discharge path. The output of the signal conditioning circuit is a negative
pulse whose duration width is proportional to the amplitude of the surge current. is used to
protect the 2N2222 NPN transistor. The collector of yields 3 V, recognized as logic high in
normal conditions. The voltage of is logic low when it is above the threshold voltage of
(typically 0.7 V). is a pull up resistor, and is used to reduce noise and chattering. Let ,
Sensors 2020, 20, 2310 8 of 17

R3 —there is no other discharge path. The output of the signal conditioning circuit is a negative pulse
whose duration width is proportional to the amplitude of the surge current. TVS1 is used to protect
the Q1 2N2222 NPN transistor. The collector of Q1 yields 3 V, recognized as logic high in normal
conditions. The voltage of V3 is logic low when it is above the threshold voltage of Q1 (typically 0.7 V).
R4 is a pull up resistor, and C2 is used to reduce noise and chattering. Let V3,peak be the peak value of
V3 . Then, we have the following relationship for the collector output of Q1 :

R2 R3 V3,peak
T= C1 × ln( ) (5)
R2 + R3 Vth

T is 2020,
whereSensors duration width (surge detection interrupt time) of the logic low state of a negative
20, x FOR PEER REVIEW
pulse
9 of 18
used as an input to the microcontroller, R2 is 1 MΩ, R3 is 100 kΩ, C1 is 0.1 µF, V3,peak is the peak
(toroidal
voltage charged coil)
to Caccording
1 , and Vthtoisthe
the amplitude of thebetween
cut-off voltage surge current,
the baseand andthe
thetime duration
emitter of theTQwere
1 2N2222
measured through an experiment and are shown in Table 5. Figure 9 illustrates
NPN transistor and is approximately 0.2 V. V1,peak and V3,peak of the current transformer (toroidal coil) the output
characteristics
according of the signal
to the amplitude ofconditioning circuit. and the time duration T were measured through
the surge current,
an experiment and are shown in Table 5. Figure 9 illustrates the output characteristics of the signal
Table 5. Experimental data of , , , , and T for different amplitudes of surge current.
conditioning circuit.
Lightning Surge Current (kA) T (ms) , (V) , (V)
0.25
Table 5. Experimental 5.29T for different
data of V1,peak , V3,peak , and 5.4amplitudes of surge
0.3 current.
0.5 18.00 11.1 0.85
Lightning Surge Current
1 (kA) T (ms) 32.00 V1,peak
22 (V) V3,peak (V)
2.24
0.25 2 5.2939.00 42.2
5.4 5.24 0.3
0.5 3 18.0047.50 11.1
66.2 7.7 0.85
1 32.00 22 2.24
4 50.00 90 10.6
2 39.00 42.2 5.24
3 5 47.5052.00 130
66.2 13.7 7.7
4 6 50.0053.50 15190 16.210.6
5 7 52.0056.00 130
175 19.613.7
6 10 53.5062.00 151
235 28.616.2
7 56.00 175 19.6
20 74.09 435 58.6
10 62.00 235 28.6
20 30 74.0979.48 635
435 88.658.6
30 40 79.4883.29 835
635 118.688.6
40 50 83.2986.23 835
1035 118.6
148.6
50 60 86.2388.63 1035
1235 148.6
178.6
60 88.63 1235 178.6
70 90.65 1435 208.6
70 90.65 1435 208.6
80 80 92.4092.40 1635
1635 238.6
238.6
90 90 93.9593.95 1835
1835 268.6
268.6
100 100 95.4695.46 2035
2035 301.6
301.6

100 400

90 360

80 320
Duration width T (ms)

70 280
Voltage of V 3 (V)

60 240

50 200
V
3
40 160
Time
30 120

20 80

10 40

0 0
0 10 20 30 40 50 60 70 80 90 100
Lightning surge current (kA)

Figure 9. Output characteristics of signal conditioning circuit.

Figure 9. Output characteristics of signal conditioning circuit.

The output of the current transformer (toroidal coil) due to the surge current is proportional to
the time derivative of the surge current, as shown in Equation (3). The test setup is shown in
Figure 10.
The output waveforms measured using three cores and distribution of current using the AWG9
Sensors 2020, 20, 2310 9 of 17

The outputSensors
of the2020, current transformer
20, x FOR PEER REVIEW (toroidal coil) due to the surge current is10proportional
of 18 to the
time derivativemagnetic
of the saturation
surge current, as shown in Equation (3). The test setup is shown
at 100 A, as shown in Figure 11c, but magnetic saturation was observed at 1.6 in Figure 10.
kA, as shown in Figure 11d.

Sensors 2020, 20, x FOR PEER REVIEW 10 of 18

magnetic saturation at 100 A, as shown in Figure 11c, but magnetic saturation was observed at 1.6
kA, as shown in Figure 11d.

Figure 10. Experimental test setup

Figure 10. Experimental for for
test setup secondary output
secondary output of toroidal
of toroidal coil type
coil type current current
transformer of transformer
SCDS.
of SCDS.

The output waveforms measured using three cores and distribution of current using the AWG9
and AWG24 cables showed no magnetic saturation at 100 A and 1.6 kA, as shown in Figure 11a,b. The
output waveform measured using one core and without current distribution does not show magnetic
saturation at 100 A, as shown in Figure 11c, but magnetic saturation was observed at 1.6 kA, as shown
Figure 10. Experimental test setup for secondary output of toroidal coil type current transformer of
in Figure 11d. SCDS.

(a) (c)

(b) (d)
(a) (c)
Figure 11. (a) Secondary output characteristics of a toroidal coil type current sensor with three cores
and current distribution using AWG9 and AWG24 wires when the surge current was 100 A. No
magnetic saturation was observed; (b) Secondary output characteristics of a toroidal coil type current
sensor with three cores and current distribution using AWG9 and AWG24 wires when the surge
current was 1.6 kA. No magnetic saturation was observed; (c) Secondary output characteristics of a
toroidal coil type current sensor that used one core and did not distribute current when the surge
current was 100 A. No magnetic saturation was observed; (d) Secondary output characteristics of a

(b) (d)

Figure 11. (a)Figure 11. (a) Secondary

Secondary output characteristics
output characteristics of a toroidal
of a toroidal coilcoil
typetype currentsensor
current sensor with
withthree cores
three cores and
and current distribution using AWG9 and AWG24 wires when the surge current was 100 A. No
current distribution using AWG9 and AWG24 wires when the surge current was 100 A. No magnetic
magnetic saturation was observed; (b) Secondary output characteristics of a toroidal coil type current
saturation was observed;
sensor with three(b)cores
Secondary output
and current characteristics
distribution using AWG9ofand a toroidal coil when
AWG24 wires type the
current
surge sensor
with three cores andwas
current current
1.6 kA.distribution using AWG9
No magnetic saturation and AWG24
was observed; wires output
(c) Secondary whencharacteristics
the surge current
of a was
toroidal coil
1.6 kA. No magnetic type current
saturation sensor
was that used(c)
observed; oneSecondary
core and didoutput
not distribute current when
characteristics ofthe surge
a toroidal coil
current was 100 A. No magnetic saturation was observed; (d) Secondary output characteristics of a
type current sensor that used one core and did not distribute current when the surge current was
100 A. No magnetic saturation was observed; (d) Secondary output characteristics of a toroidal coil
type current sensor that used one core and did not distribute current when the surge current is 1.6 kA.
Magnetic saturation was observed.
Sensors 2020, 20, x FOR PEER REVIEW 11 of 18

toroidal coil type current sensor that used one core and did not distribute current when the surge
current is 1.6 kA. Magnetic saturation was observed.
Sensors 2020, 20, 2310 10 of 17

The test equipment used in this experiment is shown in Table 6. As the secondary side of
the toroidal
The testcoil has a different
equipment used reference point fromisthe
in this experiment ground
shown of the 6.
in Table signal conditioning
As the secondarycircuit,
side of the
it was measured
toroidal coil has ausing a high-voltage
different differential
reference point probe
from the [25,26].
ground of the signal conditioning circuit, it was
measured using a high-voltage differential probe [25,26].
Table 6. Test equipment to measure toroidal coil output and signal conditioning circuit of SCDS.
Table 6. Test equipment to measure toroidal coil output and signal conditioning circuit of SCDS.
Specification
Test Equipment Maker Model
Test Equipment Maker Model Voc (1.2/50 µs):15 kV
Specification
Lightning surge simulator Noiseken LSS-15AX
IscVoc
(8/20 µs):µs):
(1.2/50 7.515
kAkV
Lightning surge simulator Noiseken LSS-15AX
Impulse current generator HAEFELY SSG series Isc Isc
(8/20 µs):
(8/20 µs):120
7.5kA
kA
Impulse current generator HAEFELY SSG series Isc (8/20 µs): 120 kA
Sapphire
High voltage
High voltagedifferential probe
differential probe Sapphire Instruments SI-9010
SI-9010 ± 7,000 V
±7000 V
Oscilloscope Instruments
Yokogawa DLM2054 2.5 Gs, 500 MHz
Oscilloscope
Scope probe Yokogawa
Yokogawa DLM2054
701939 2.5600
Gs,V,500
600MHz
MHz
Scope probe Yokogawa 701939 600 V, 600 MHz
Figure 12 illustrates the manner by which the amplitude information of the surge current is
Figure 12 illustrates the manner by which the amplitude information of the surge current is
translated to the duration width of a negative pulse generated by the signal conditioning circuit. The
translated to the duration width of a negative pulse generated by the signal conditioning circuit. The
amplitude of voltage V is converted to T. As the V voltage amplitude increases, the converted T
amplitude of voltage 3 is converted to T. As the 3 voltage amplitude increases, the converted T
increases, as shown in Equation (4), making processing easier in the microcontroller.
increases, as shown in Equation (4), making processing easier in the microcontroller.

Figure 12.
Figure Amplitude of
12. Amplitude of surge
surge current
current and
and duration
duration width
width of
of negative
negative pulse
pulse generated
generated by
by signal
signal
conditioning circuit.
conditioning circuit.

2.5. Calculation Principle of the Predictive Lifetime and Software Algorithm for the Expected Lifetime of
2.5. Calculation Principle of the Predictive Lifetime and Software Algorithm for the Expected Lifetime of the
the SPD
SPD
2.5.1. Calculation Principle of the Predictive Lifetime of the SPD
2.5.1. Calculation Principle of the Predictive Lifetime of the SPD
The predictive lifetime of the SPD using the SCDS proposed in this study can be calculated based
on theThe predictive
lifetime of thelifetime of the
MOV. The SPD using
lifetime in thethe SCDS proposed
derating curves of in this
the MOVstudy can be calculated
decreases based
in proportion to
on the lifetime of the MOV. The lifetime in the derating curves of the MOV decreases in proportion
the square of the current, as shown in Table 7. It can be expressed as a trend line, as shown in Figure 13.
to the square of the current, as shown in Table 7. It can be expressed as a trend line, as shown in
FigureTable
13. 7. In 20 kA MOV lifetime characteristics according to the surge current and number of surges.
1
imov 7.
Table Surge
20Current
kA MOV (A)
lifetime characteristics according
(Surge
Endurable Number of Surges
Current)2 to the surge current and number of surges.

90 Surge Current 1.235 × 10−4 1,000,000

Endurable Number of
200 2.500 × 10−5 100,000
(A) ( ) Surges
500 4.000 × 10−6 10,000
2000 90 1.235
2.500 ××10
−4
10−7 1000,000 1000
7000 2.041 ××10 −8
10−5 100
200 2.500 100,000
20,000 −9
2.500 × 10−6 10
500 4.000 × 10 10,000
40,000 6.250 × 10−10 1
2000 2.500 × 10 −7
1000
Sensors 2020, 20, x FOR PEER REVIEW 12 of 18

7000 2.041 × 10−8 100

20000 2.500 × 10−9 10
Sensors 2020, 20, 2310
40000 6.250 × 10 −10
1 11 of 17

6 6
10 10

5 5
10 10

Endurable number of surges

4 4
10 10

3 3
10 10

2 2
10 10

In 20 kA MOV lifetime
1 Trend line of MOV lifetime 1
10 10

0 0
10 -9 -8 -7 -6 -5 -4 10
10 10 10 10 10 10

1/(Surge current2)

Figure13.
Figure Trendline
13.Trend lineof
ofMOV
MOVlifetime
lifetimeaccording
accordingto
tosurge
surgecurrent
currentand
andnumber
number of
of surges.
surges.

The equation of the trend line of the MOV lifetime can be represented as
The equation of the trend line of the MOV lifetime can be represented as
= αx −−β
N= (6)
(6)
where
where x isisthe
theinverse
inverse of
of the
the square
square of
of current
current applied
applied to to the
the MOV,
MOV, and
and N
N is
is the
the endurable
endurable number
number
of surges. The constants α and β were found to be 5,012,836,137 and 2, respectively.
of surges. The constants α and β were found to be 5,012,836,137 and 2, respectively. Therefore,Therefore,
Equation
Equation(6)(6)can
canbe
berewritten
rewritten as
as !
11
N==α −−β (7)(7)
imov 2
The calculation
The calculationprinciple
principlefor
forthe
the predictive
predictivelifetime
lifetimeof ofthe
the SPD
SPD in
in the
the proposed
proposed SCDSSCDS can
can be
be
expressed
expressed as as
1
Ln+1 = Ln − 1 (8)
= N
− (8)
where Ln+1 is the estimated value of the SPD lifetime after the surge input, Ln is the SPD lifetime value
1
before the surge
where is theinput, and the
estimated initial
value value
of the SPDoflifetime (L0 =the
Ln is 1 after 1).surge
Furthermore,
input, Nisis theSPD
the decrease
lifetimein
the lifetime
value before of
thethe MOV
surge according
input, and thetoinitial
the surge
valueinput,
of is 1 ( N=is1).
where determined
Furthermore,from Equation (7). By
is the decrease
substituting
in the lifetimeEquation (7) into
of the MOV Equation
according to(8),
thethe equation
surge input,can be written
where as
N is determined from Equation (7).
By substituting Equation (7) into Equation (8), the equation
1 can be written as
Ln+1 = Ln −  (9)
1

= − α i 1 2 −β
mov1 (9)
−
imov can be expressed as Equation (10), depending on the number of phase lines.
can be expressed as Equation (10), depending on the number of phase lines.
I
imov = total (10)
= Pn (10)

where Itotal isisthe

where thetotal
totalsurge
surgecurrent
currentflowing
flowing from
from all
all phase lines to
phase lines to the
the PE
PEpath, and Pn is
path,and is the
the total
total
numberof
number ofphase
phaselines.
lines.
The final equation
The final equation for for the
the predictive
predictive lifetime
lifetime can
can be
be expressed
expressed as
as

1
Ln+1 = Ln −   (11)
Pn 2
α −β
Itotal 2
Sensors 2020, 20, 2310 12 of 17

2.5.2. Software Algorithm for the Predictive Lifetime of the SPD

As power is applied to the SCDS, the microcontroller’s timer, interrupt, and embedded electrically
erasable programmable read-only memory (EEPROM) are initialized. The surge count data of the
Sensors 2020, 20, x FOR PEER REVIEW 13 of 18
EEPROM is read and displayed on the LCD, and sleep mode is activated to minimize battery power
consumption. When the function key is pressed, the microcontroller exits sleep mode and displays
1
the predictive lifetime of the SPD for five = −
seconds. The surge count is displayed again, and the
(11)
microcontroller returns to sleep mode. If surge interrupt is detected − as ‘low (0 V)’ from the signal
conditioning circuit in the main loop, the ‘low (0 V)’ holding time is measured by the internal 61-µs
timer (2/clock: 32.768 kHz) and translated to the amplitude of the surge current. If the surge amplitude
2.5.2.
is Software
below 500 A, itAlgorithm for theaccording
will be ignored, PredictivetoLifetime ofthe
Table 8. If thesurge
SPD current is above 500 A, the predictive
lifetime
As of the SPD
power is will be recalculated
applied to the SCDS,usingthe
themicrocontroller's
surge current amplitude. The number
timer, interrupt, of surges
and and
embedded
predictive
electricallylifetime
erasable areprogrammable
stored on the internal EEPROM.
read-only memoryThe increasedare
(EEPROM) surge count is displayed
initialized. The surge on the
count
LCD. The software algorithm for the predictive lifetime of the SPD is shown in
data of the EEPROM is read and displayed on the LCD, and sleep mode is activated to minimize Figure 14.
battery power consumption. When the function key is pressed, the microcontroller exits sleep mode
Table 8. Typical values of I and Imcw for IEC62561-6.
and displays the predictive lifetime of the SPD fortcfive seconds. The surge count is displayed again,
and the microcontroller returns
Application to sleep mode. If surge interrupt is
Itc Value Imcwdetected
Value as ’low (0 V)’ from the
signal conditioning circuit in the main 1 kAloop, the ’low (0 V)’ holding time is measured by the 100internal
kA
LPS conductor -
61-µs timer (2/clock: 32.768 kHz) and - - - -
8/20 translated
µs to the amplitude of the surge current. If the surge
10/350 µs
amplitude is below 500 A, it
500 A will be ignored, according
20 kA to Table
40 kA 8. If the
60 kAsurge current
80 kA is above
100 kA A,
500
SPD conductor
the predictive lifetime of8/20
theµs -
SPD will be recalculated
8/20 µs using 8/20the
µs surge current
8/20 µs amplitude.
8/20 µs The number
8/20 µs
of surges and predictive
LPS and SPD lifetime are stored
1 kA on the internal EEPROM. The increased surge 100 kA is
count
- - - - -
displayed on the
conductors LCD. The software algorithm
8/20 µs for the predictive lifetime of the SPD is shown
10/350 µs in
Figure 14.

Figure
Figure 14. Software algorithm
14. Software algorithm for
for the
the predictive
predictive lifetime
lifetime of
of the
the SPD.
SPD.

The proposed SCDS displays the surge count on the LCD in normal conditions. If a surge current
is detected or the function button is pressed briefly, the lifetime is displayed for five seconds and the
surge count is displayed. The display windows are designed as shown in Figure 15.
Sensors 2020, 20, 2310 13 of 17

The proposed SCDS displays the surge count on the LCD in normal conditions. If a surge current
isSensors
detected
2020, or
20, the function
x FOR button is pressed briefly, the lifetime is displayed for five seconds and
PEER REVIEW 14 the
of 18
Sensors 2020, 20, x FOR PEER REVIEW 14 of 18
surge count is displayed. The display windows are designed as shown in Figure 15.

(a) (b) (c)

(a) (b) (c)

Figure 15.(a)
Figure15. (a)Surge
Surgecount
countmode
mode(b)
(b)Lifetime
Lifetimemode
mode(c)
(c)End
Endofoflifetime
lifetimemode.
mode.
Figure 15. (a) Surge count mode (b) Lifetime mode (c) End of lifetime mode.
Figure
Figure15a 15ashows
showsthethesurge
surgecount
countmode;
mode;‘C’ ‘C’on
onthetheleft
leftside
sideindicates
indicatescount countmode.
mode.Figure
Figure15b15b
shows Figure
the 15a
lifetime shows
mode; the
‘L’ surge
on the count
left mode;
side ‘C’
indicates on the
lifetimeleft side
mode. indicates
If the count
lifetime is mode.
less than Figure
10%, 15b
‘F’
shows the lifetime mode; ‘L’ on the left side indicates lifetime mode. If the lifetime is less than 10%,
shows
in‘F’the the
upper lifetime
left mode;
corner will‘L’
beon the left
displayed, side indicates
indicating the lifetime
end of mode.
lifetime, If the
as lifetime
shown in is less
Figure than
15c. 10%,
in the upper left corner will be displayed, indicating the end of lifetime, as shown in Figure 15c.
‘F’ inThethe upper leftSCDS corner will be displayed, indicating the end of of lifetime,Whenas shownfunction
in Figure 15c.
Theproposed
proposed SCDSisisdesigned
designedtotobe beused
usedwith
withvarious
varioustypes
types ofSPD. SPD. Whenthe the functionkey keyofof
the The proposed SCDS is designed to be used with various types of SPD. When the function key of
theSCDS
SCDSisispressed
pressedforformore
morethan
thanten tenseconds,
seconds,ititactivates
activatesthetheSPDSPDselection
selectionmode.mode.AAshortshortpress
pressofof
the
the SCDS is pressed for more than ten seconds, it activates the SPD selection mode. A short press of
thefunction
functionkey keychanges
changesthe
theSPD
SPDmodemodeand andpressing
pressingfor formore
morethan thanthree
threeseconds
secondsselects
selectsit.it.The
TheSPD
SPD
the function key
selection changesinthe SPD mode and pressing for more than three secondsSPD selects it. The SPD
selectionmode modeisisshown
shown inFigure
Figure16. 16.The
Thefour
fournumbers
numbers shownshown on on the
the LCD
LCD are are SPDmodel
modelnames.names.
selection
The mode is shown in Figure 16. The four numbers shown on the LCD are SPD model names.
Thefirst
firsttwo
twonumbers
numbersindicate
indicatesingle-phase
single-phase(22) (22)ororthree-phase
three-phase(34) (34)operation.
operation.The Thelast
lasttwo
twonumbers
numbers
The firstthe
indicate two numbers
capacity of indicate
the SPD; single-phase
04 indicates (22) orcapacity,
20-kA three-phase and (34)
08 operation.
indicates The last
40-kA two numbers
capacity.
indicate the capacity of the SPD; 04 indicates 20-kA capacity, and 08 indicates 40-kA capacity.
indicate the capacity of the SPD; 04 indicates 20-kA capacity, and 08 indicates 40-kA capacity.

(a) (b)
(a) (b)

(c) (d)
(c) (d)
Figure
Figure16. (a)In 20-kA
16.(a) 20-kAsingle-phase
single-phaseSPD
SPDselection
selectionmode (b)In 20-kA
mode(b) 20-kAthree-phase
three-phaseSPD
SPDselection
selectionmode
mode
Figure
(c) I 16.
40-kA (a) 20-kA
single-phasesingle-phase
SPD SPD
selection selection
mode (d) I mode
40-kA(b) 20-kA
three-phase three-phase
SPD SPD
selection selection mode
mode.
(c) n 40-kA single-phase SPD selection mode (d) n 40-kA three-phase SPD selection mode.
(c) 40-kA single-phase SPD selection mode (d) 40-kA three-phase SPD selection mode.
3. Results
3. Results
3. Results
3.1. Expected Lifetime of the SPD
3.1. Expected Lifetime of the SPD
3.1. Expected Lifetime of the SPD
IEC62561-6 Test Results
IEC62561-6 Test Results
IEC62561-6 Test Results
The IEC62561-6 international standard specifies requirements and tests for devices that count
surges.The IEC62561-6
Surge countersinternational standard
can be installed specifies
and used requirements
on the conductor ofandthetests
LPS for devicesprotection
(lightning that count
The IEC62561-6 international standard specifies requirements and tests for devices that count
surges. or
system) Surge counters
the SPD. can betoinstalled
According and used
this standard, on the conductor
the operating thresholdofcurrent
the LPSI (lightning protection
of the surge counter
surges. Surge counters can be installed and used on the conductor of the LPStc (lightning protection
system) or the SPD. According to this standard, the operating threshold current of the surge
system) or the SPD. According to this standard, the operating threshold current of the surge
counter is defined as 500 A when used with the SPD and 1 kA when used with the LPS. The surge
counter is defined as 500 A when used with the SPD and 1 kA when used with the LPS. The surge
counter should not operate at half value of . is the maximum surge current that the surge
counter should not operate at half value of . is the maximum surge current that the surge
counter can withstand. Typical values are shown in Table 8 [27].
counter can withstand. Typical values are shown in Table 8 [27].
Sensors 2020, 20, 2310 14 of 17

is defined as 500 A when used with the SPD and 1 kA when used with the LPS. The surge counter
should not operate at half value of Itc . Imcw is the maximum surge current that the surge counter can
withstand. Typical values are shown in Table 8 [27].
In the proposed SCDS, the value of Itc was designed to be 500 A, according to Table 8. LSS-15AX
(15 kV, 7.5 kA) by Noiseken was used for generation of surges. The results of the experiment meet the
requirements of IEC62561-6, as shown in Table 9 [27].

Table 9. Test results of Itc .

Surge Current 8/20 µs Number of Surge Tests Count Results Test Results
250 A (positive) 10 X (no count) Pass
250 A (negative) 10 X (no count) Pass
400 A (positive) 10 X (no count) Pass
400 A (negative) 10 X (no count) Pass
500 A (positive) 10 O (10 times) Pass
500 A (negative) 10 O (10 times) Pass

Imcw was also tested by the National Accredited Certification Body and the SSG Series from
HAEFELY was used for generation of the impulse current. Operation was normal with no damage
when the tests were performed by applying 8/20 µs 100 kA surge current to the SCDS. Surge currents
of both polarities were tested.

3.2. Results of the Predictive Lifetime Test of the SPD

To test the predictive lifetime of the SPD, the SCDS, configured as a three-phase four-wire system,
was connected, and the lifetime reduction test was performed by an authorized institution using an
impulse current generator (SSG Series) to vary the current amplitude. The test results are shown in
Table 10, with error tolerances within 10%.

Table 10. Test results of the predictive lifetime of the SPD due to lightning surge currents.

Surge Surge Decreased

Sample #1 Sample #2 Sample #3 Sample #4
Current Current Per Predictive
(%) (%) (%) (%)
8/20 µs Path Lifetime (%)
1 kA 250 A 0.00 0 0 0 0
5 kA 1.25 kA 0.03 0.03 0.03 0.03 0.03
10 kA 2.5 kA 0.12 0.11 0.12 0.13 0.12
20 kA 5 kA 0.50 0.46 0.49 0.53 0.51
30 kA 7.5 kA 1.15 1.06 1.11 1.22 1.19
40 kA 10 kA 2.08 1.95 2.01 2.24 2.15
50 kA 12.5 kA 3.32 3.06 3.14 3.52 3.44
60 kA 15 kA 4.93 4.52 4.67 5.35 5.20
70 kA 17.5 kA 6.96 6.35 6.50 7.53 7.23
80 kA 20 kA 9.49 8.78 9.19 10.23 9.79
90 kA 22.5 kA 12.66 11.66 12.05 13.69 12.98
100 kA 25 kA 16.61 15.30 15.87 17.59 17.20

3.3. Battery Power Consumption Test Results

The proposed SCDS is powered by a built-in 3 V coin-cell type battery without an external power
supply, so it can be operated at ultra-low power for a long period of time. For the power consumption
test, a PAS40-18 (40 V/18 A) from KIKUSHI Electronics Corp (Kanagawa County, Japan). was used as
a power supply, and a GDM-8261A by GWINSTEK (Xinbei, Taiwan) was used as an ampere-meter.
Figure 17 shows the test setup.
3.3. Battery Power Consumption Test Results
The proposed SCDS is powered by a built-in 3 V coin-cell type battery without an external power
supply, so it can be operated at ultra-low power for a long period of time. For the power consumption
test, a PAS40-18 (40 V/18 A) from KIKUSHI Electronics Corp (Kanagawa County, Japan). was used
Sensors 2020, 20, 2310 15 of 17
as a power supply, and a GDM-8261A by GWINSTEK (Xinbei, Taiwan) was used as an ampere-meter.
Figure 17 shows the test setup.

Power supply Current meter

SCDS
DC 3V

(a) (b)
Figure
Figure 17.
17. (a)
(a)Battery
Batteryconsumption
consumptiontest
testsetup
setup(b)
(b)Battery
Battery consumption
consumption test
test configuration.
configuration.

After applying
After applying 33 VDCVDC fromfrom thethe power
power supply,
supply, the
the measured
measured current
current inin sleep
sleep mode
mode waswas
approximately 7.2
approximately 7.2µAµAand andthethe measured
measured current
current in wakeup
in wakeup modemode
was was approximately
approximately 100 The
100 µA. µA.
The wakeup
wakeup mode mode period
period is 75isms
75 at
ms20atkA.
20 kA. Assuming
Assuming thatthat
the the
SCDS SCDS is detected
is detected 100100 times
times at 20
at 20 kA,kA,
it isit
is 7.5
7.5 s, so
s, so it can
it can be regarded
be regarded as not
as not affecting
affecting the the power
power consumption
consumption of battery.
of the the battery.
AndAnd the battery
the battery life
life was
was calculated
calculated to beto11.1
be years,
11.1 years, as shown
as shown in Equation
in Equation (12) Thus,
(12) [28]. [28]. Thus, the target
the target lifetime
lifetime of seven
of seven years
years (typically
(typically the maximum
the maximum lifetimelifetime of an is
of an SPD) SPD) is guaranteed.
guaranteed.

Battery ( (mAH
Capacity ) )
= fe = × 0.7 ÷ 24 (ℎ ) × 365( ) ≅ 11.10 (12)
Battery Li (
Current Consumption (mA ) ) × 0.7 ÷ (24 (hour) × 365(day))  11.10 years (12)

In Equation (12), a constant of 0.7 is used as a margin factor to consider environmental conditions
In Equation (12), a constant of 0.7 is used as a margin factor to consider environmental conditions
of humidity and temperature.
of humidity and temperature.
4. Discussion
4. Discussion
It has been confirmed that the proposed SCDS operates according to the amplitude of lightning
It has been confirmed that the proposed SCDS operates according to the amplitude of lightning
surge currents and has a current detection error tolerance of approximately 10%. In practical
surge currents and has a current detection error tolerance of approximately 10%. In practical
applications, tolerances near 10% are not particularly critical. Currently, lifetime indicators are rarely
applications, tolerances near 10% are not particularly critical. Currently, lifetime indicators are rarely
used owing to relatively high cost compared to the SPD, and low-cost surge counters are used instead.
used owing to relatively high cost compared to the SPD, and low-cost surge counters are used instead.
The surge counters count detections of current above the threshold surge current, but do not indicate
The surge counters count detections of current above the threshold surge current, but do not indicate
the lifetime of the SPD. Table 11 shows a comparison of performance, cost, and market applicability
the lifetime of the SPD. Table 11 shows a comparison of performance, cost, and market applicability for
for the proposed SCDS with commonly used lightning counters and other SCDSs.
the proposed SCDS with commonly used lightning counters and other SCDSs.
Table 11. Performance and cost comparison of SCDSs.
Table 11. Performance and cost comparison of SCDSs.
SPD
Surge
Surge Current
Current SPD Predictive General
General
SCDS
SCDS Polarity
Polarity Lifetime
Predictive Cost
Cost
Count Measurement Market
Count Measurement Market
Lifetime Very low (tens of
Proposed SCDS O O X O Applicable
Proposed USD)low
Very
O O X O Applicable
SCDS
Surge counter O X X X (tens
Very lowof USD)
(tens of
Applicable
USD)
Surge Very low
SCDS with O X X X High (hundreds of Applicable
Not
counter O O O O (tens of USD)
Rogowski coil USD) applicable
SCDS with High
SCDS with
Very Not
Not
Rogowski O O OO O O O O (hundreds of
high(thousands of
expensive CT
USD)
applicable
applicable
coil USD)

5. Conclusions
In this study, we proposed a low-cost surge current detection sensor, which can predict lifetime
for maintaining surge protective devices by detecting the amplitude of surge currents and number of
surges. The proposed SCDS improves on conventional surge counters that display only the number
of surges. The proposed SCDS uses a low-cost toroidal coil to measure the surge current, and a new
measurement method to solve the problem of magnetic saturation caused by high surge current. In
Sensors 2020, 20, 2310 16 of 17

addition, we proposed both a method and a software algorithm for calculating the predictive lifetime
of an SPD in a microcontroller through a signal conditioning circuit that converts the amplitude of
the surge current into the duration width of a negative pulse. The proposed SCDS is expected to
greatly improve the maintenance efficiency of SPDs. In future research, we plan to study the predictive
lifetime of a communication SPD.

Author Contributions: Conceptualization, Y.L. and Y.S.L.; methodology, Y.L.; software, Y.L.; validation, Y.L.;
formal analysis, Y.L.; investigation, Y.L.; writing—original draft preparation, Y.L.; writing—review and editing,
Y.L. and Y.S.L; supervision, Y.S.L.; project administration, Y.L.; funding acquisition, Y.S.L. and Y.L. All authors
have read and agreed to the published version of the manuscript.
Funding: This work was supported by Inha University Research Grant.
Acknowledgments: The authors would like to thank Ki Won Choi and Kyu Hong Shim for helping with the test
and data collection.
Conflicts of Interest: The authors declare no conflict of interest.

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